KTM 525 XC ATV 2008 User manual

OWNER'S MANUAL 2008
450 XC ATV
525 XC ATV
ART. NO. 3211251en

DEAR KTM CUSTOMER 1
'($5 .70 &86720(5
Congratulations on your decision to buy a KTM ATV. You are now the owner of a state-of-the-art sports ATV that will give you enormous
pleasure if you service and maintain it accordingly.
We wish you great pleasure riding the vehicle!
Enter the serial numbers of your vehicle below.
Chassis number ( P. 12) Dealer's stamp
Engine number ( P. 12)
Key number ( P. 12)
The owner's manual corresponded to the latest state of this series at the time of printing. Slight deviations resulting from continuing
development and design can however not be completely excluded.
All specifications are not binding. KTM Sportmotorcycle AG in particular reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as printing and other errors. The models portrayed partly contain special
equipment that does not belong to the regular scope of delivery.
© 2007 by KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, is permitted only with the express written permission of the copyright owner.
ISO 9001(12 100 6061)
Within the meaning of the international quality management standard ISO 9001, KTM uses quality assurance processes
that lead to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

CONTENTS 2
&217(176
MEANS OF REPRESENTATION ............................................ 4
IMPORTANT NOTES............................................................ 5
Overview of warning labels................................................ 8
VIEW OF VEHICLE............................................................. 10
Vehicle view, front left ................................................... 10
View of vehicle, rear right ............................................... 11
LOCATION OF SERIAL NUMBERS ...................................... 12
Chassis number............................................................. 12
Type label..................................................................... 12
Key number .................................................................. 12
Engine number.............................................................. 12
Setting number, front shock absorber .............................. 12
Setting number, rear shock absorber ............................... 13
OPERATING ELEMENTS.................................................... 14
Clutch lever .................................................................. 14
Reverse gear release lever .............................................. 14
Hand brake lever, parking brake...................................... 14
Throttle lever................................................................. 14
Light switch.................................................................. 15
ENG.bSTOPbSwitch ........................................................ 15
Electric starter button .................................................... 15
Ignition switch .............................................................. 15
Indicator lamp overview ................................................. 15
Emergency OFF switch with rip cord................................ 16
Opening filler cap.......................................................... 16
Closing filler cap ........................................................... 16
Fuel tap........................................................................ 16
Choke........................................................................... 17
Hot start button............................................................. 17
Shift lever..................................................................... 17
Foot brake pedal ........................................................... 17
TIPS ON PUTTING INTO OPERATION ................................. 18
Advice on first use......................................................... 18
Running in the engine.................................................... 19
RIDING INSTRUCTIONS .................................................... 20
Checks before putting into operation ............................... 20
Starting ........................................................................ 20
Starting up ................................................................... 21
Shifting ........................................................................ 21
shifting to reverse gear................................................... 22
Disengaging reverse gear ................................................ 22
Braking ........................................................................ 22
Riding .......................................................................... 23
Riding in bends............................................................. 23
Riding downhill ............................................................. 24
Riding uphill................................................................. 24
Riding perpendicular to the slope.................................... 25
Turning on slopes .......................................................... 25
Riding through water ..................................................... 25
Switching off the engine ................................................ 26
Stopping, parking .......................................................... 26
Refueling...................................................................... 27
GREASING AND SERVICE TABLE ....................................... 28
Important maintenance work to be carried out by an
authorized KTM workshop. ............................................. 28
Important maintenance work to be carried out by an
authorized KTM workshop. (as additional order)................ 29
Important checks and maintenance work to be carried
out by the rider. ............................................................ 29
MAINTENANCE ON CHASSIS AND ENGINE ........................ 31
Jacking up the vehicle ................................................... 31
Removing the vehicle from the work stand ....................... 31
Basic information on changing the chassis settings........... 31
Adjusting front shock absorber compression damping ....... 31
Adjusting front shock absorber rebound damping.............. 32
Adjusting front shock absorber cross over......................... 33
Adjusting front shock absorber spring preload .................. 33
Adjusting rear shock absorber compression damping......... 34
Adjusting rear shock absorber rebound damping ............... 35
Adjusting rear shock absorber spring preloadbx............... 36
Removing the rear shock absorberbx.............................. 37
Installing the rear shock absorberbx............................... 37
Toe, checkingbx........................................................... 37
Adjusting the toebx...................................................... 38
Checking/adjusting camberbx........................................ 40
Fork offset .................................................................... 41
Adjusting the fork offsetbx............................................ 41
Toe width of rear axle..................................................... 41
Adjusting the toe width of rear axlebx............................. 41
Handlebar position ........................................................ 42
Adjusting handlebar positionbx...................................... 43
Checking play in gas Bowden cable ................................. 43
Adjusting play in gas Bowden cable................................. 44
Checking the play in the Bowden cable using the reverse
gear release lever........................................................... 44
Adjusting the play in the Bowden cable using the reverse
gear release lever........................................................... 44
Checking chain dirt ....................................................... 45
Cleaning the chain......................................................... 45
Checking the chain tension ............................................ 45
Checking rear sprocket / engine sprocket for wear ............. 45
Checking chain wear...................................................... 46
Adjusting chain tension.................................................. 46
Greasing the rear wheel eccentric element ....................... 47
Checking brake discs ..................................................... 47
Checking free play of hand brake lever............................. 48
Adjusting basic position of handbrake lever...................... 48
Checking front brake fluid level....................................... 48
Topping up the front brake fluidbx................................. 49
Checking the front brake linings...................................... 49
Removing front brake liningsbx...................................... 50
Mounting front brake liningsbx...................................... 50
Changing the front brake liningsbx................................. 51
Checking free play of foot brake lever .............................. 52
Adjusting basic position of footbrake leverbx................... 52
Checking rear brake fluid level........................................ 52
Topping up brake fluid of front brakebx.......................... 53
Checking rear brake linings ............................................ 54
Removing rear brake liningsbx....................................... 54
Mounting rear brake liningsbx....................................... 55
Changing rear brake liningsbx........................................ 55
Removing wheel/wheels.................................................. 56
Mounting wheel/wheels .................................................. 56
Tire condition checking.................................................. 57
Checking tire air pressure............................................... 57
Removing the battery..................................................... 57
Installing the battery...................................................... 58
Recharging the batterybx.............................................. 58
changing main fuse ....................................................... 59
Changing the fuses of individual power-consuming
components .................................................................. 59
Ignition curve plug connection........................................ 60
Changing ignition curve.................................................. 61

CONTENTS 3
Removing the seat ......................................................... 61
Mounting the seat ......................................................... 61
Removing the radiator spoiler ......................................... 61
Installing the radiator spoiler .......................................... 62
Removing the front cover................................................ 62
Installing the front cover ................................................ 62
Removing the front trim ................................................. 63
Installing the front trim .................................................. 63
Removing the rear fender ............................................... 63
Installing the rear fender ................................................ 64
Removing the engine guard ............................................ 65
Installing the engine guard ............................................. 65
Removing the air filterbx............................................... 65
Installing the air filterbx............................................... 66
Cleaning air filterbx...................................................... 66
Adjusting basic position of clutch lever............................ 66
Checking fluid level of hydraulic clutch ........................... 66
Cooling system.............................................................. 67
Radiator fan.................................................................. 67
Checking antifreeze and coolant level .............................. 67
Checking the coolant level.............................................. 68
Draining coolantbx....................................................... 68
Filling coolant / bleeding cooling systembx..................... 69
Carburetor - idle ............................................................ 70
Carburetor - adjusting idlebx......................................... 71
Emptying the carburetor float chamberbx....................... 72
Checking engine oil level................................................ 72
Changing engine oil and oil filter, cleaning oil
screensbx.................................................................... 73
Draining engine oil, cleaning oil screensbx..................... 73
Removing the oil filterbx............................................... 74
Mounting oil filterbx..................................................... 75
Filling up with engine oilbx........................................... 75
Topping up engine oil .................................................... 76
TROUBLESHOOTING......................................................... 77
CLEANING........................................................................ 79
Cleaning the vehicle ...................................................... 79
STORAGE ......................................................................... 80
Storage......................................................................... 80
Putting the vehicle into operation after storage................. 80
TECHNICAL DATA - ENGINE.............................................. 81
Capacity - engine oil ...................................................... 81
Capacity - cooling liquid................................................. 82
TECHNICAL DATA - ENGINE TIGHTENING TORQUES.......... 83
TECHNICAL DATA - CARBURETOR..................................... 85
450/525bXCbATV ........................................................... 85
TECHNICAL DATA - CHASSIS ............................................ 86
Lighting equipment ....................................................... 87
Tires ............................................................................ 87
Capacity - fuel............................................................... 87
TECHNICAL DATA - FRONT SHOCK ABSORBER.................. 88
TECHNICAL DATA - REAR SHOCK ABSORBER.................... 89
TECHNICAL DATA - CHASSIS TIGHTENING TORQUES ........ 90
WIRING DIAGRAM ............................................................ 92
450/525bXCbATV ........................................................... 92
SUBSTANCES................................................................... 95
AUXILIARY SUBSTANCES.................................................. 97
STANDARDS..................................................................... 98
INDEX .............................................................................. 99

MEANS OF REPRESENTATION 4
0($16 2) 5(35(6(17$7,21
Symbols used
The symbols used are explained in the following.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
All work marked with this symbol requires specialist knowledge and technical understanding. In the interest of
your own safety, have these jobs done in an authorized KTM workshop! There, your vehicle will be serviced opti-
mally by specially trained experts using the specialist tools required.
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained in the following.
Specific name Identifies a specific name.
Name®Identifies a protected name.
Brand™ Identifies a brand in merchandise traffic.

IMPORTANT NOTES 5
,03257$17 127(6
Use definition
KTM ATVs are designed and built to withstand the normal stresses and strains of competitive use. The vehicles comply with currently
valid regulations and categories of the top international motorsport organizations.
Warning
Danger of accidentsಘIncorrect assessment of riding situations.
ದThe vehicle may only be ridden by persons over the age of 16.
Info
The ATV must be used only on secluded property remote from public road traffic.
The ATV is designed for off-road sport endurance competition (Enduro) and not for the predominant motocross use.
Maintenance
A prerequisite for perfect operation and prevention of wear is that the engine and chassis maintenance and adjustment work described
in the owner's manual are properly carried out. Poor adjustment and tuning of the engine and chassis can lead to damage and break-
age of components.
Using the vehicle in extreme conditions such as very muddy or wet terrain can lead to above-average wear of components such as the
transmission train or the brakes. For this reason, it may be necessary to service or replace worn parts before the limit specified in the
greasing and service table is reached.
Pay careful attention to the prescribed running-in period, inspection and maintenance intervals. If you observe these exactly, you will
ensure a much longer service life for your vehicle.
Warranty
The maintenance work prescribed in the greasing and service table must be carried out in an authorized KTM workshop and confirmed
in the customer's service record, since otherwise no warranty claims will be recognized. No warranty claims can be considered for
damage resulting from manipulations and alterations to the vehicle.
Fuel, oils, etc.
You should use the fuels, oils and greases according to specifications as listed in the owner's manual.
Spare parts, accessories
For your own safety, use only spare parts and accessories approved by KTM. KTM accepts no liability for other products and any
resulting damage or loss.
Transport
Note
Danger of damageಘDanger of damage from accidental rolling of vehicle.
ದPark the vehicle on a surface that is as horizontal as possible and activate the parking brake.
Note
Fire hazardಘSome components (engine, radiator and exhaust system) get very hot when the engine is running.
ದDo not place the vehicle where there are flammable or explosive substances.
ದSwitch off the engine.
ದTurn the handlebof the fuel tap to the OFF position. (Figureb100013-10bP. 16)
ದUse straps or other suitable devices to secure the vehicle against accidents or falling over.
ದPull the hand brake lever, push the locking pawlbdown and release the hand brake lever. (Figureb100006-10bP. 14)
Environment
Offroad riding is a wonderful sport and we naturally hope that you will be able to enjoy it to the fullest. However, it is a potential prob-
lem for the environment and can lead to conflicts with other persons. But if you use your vehicle responsibly, you can ensure that such
problems and conflicts do not have to occur. To protect the future of offroad sport, make sure that you use your ATV legally, display
environmental consciousness, and respect the rights of others.

IMPORTANT NOTES 6
Rider training
If you have never ridden an ATV before, it is important that you participate in a driver training course before you ride the vehicle for
the first time.
A professional trainer will show you how to handle your ATV safely in various riding situations and on different terrain.
Your KTM dealer will be glad to advise you.

IMPORTANT NOTES 7

IMPORTANT NOTES 8
Overview of warning labels
100106-10